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KTM 2006 660 SMC Owner's Manual

2006 ktm 660 smc motorcycle
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OWNER'S MANUAL
2006
660 SMC
ART. NR. 3.211.77EN

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Summary of Contents for KTM 2006 660 SMC

  • Page 1 OWNER’S MANUAL 2006 660 SMC ART. NR. 3.211.77EN...
  • Page 2 KTM may stop manufacturing cer- tain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly con- tain extra equipment, which is not applied to standard models.
  • Page 3 Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer.

  • Page 4: Important Limited Warranty And Limited Guarantee Information

    » IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION The KTM 660 SMC is designed and constructed to resist the usual wear and tear of normal use in competitions. The motorcycles comply with the regulations and categories currently in effect with the leading interna- tional motorcycle associations.

  • Page 5: Table Of Contents

    Chain wear ......26 General information about KTM disc brakes ..27 OPERATION INSTRUMENTS .

  • Page 6: Serial Number Locations

    » SERIAL NUMBER LOCATIONS Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page 1. Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket.

  • Page 7: Electronic Speedometer

    H displays the engine's service hours. The service hour counter starts to count as soon as you start the engine. The displayed figure cannot be changed. Service intervals are indicated in service hours for some KTM offroad motor- cycles, making the service hour counter a very practical function.
  • Page 8 » OPERATION INSTRUMENTS Activating and deactivating display modes In the display mode SPEED/H, press and hold the button for 3 seconds to access the SETUP menu. The active functions will be displayed. The blink- ing function can be activated by pressing the + button and deactivated by pressing the –...
  • Page 9 » OPERATION INSTRUMENTS LAP / LAP display mode (to view lap times) The LAP/LAP display mode will only be shown if lap times have been stored and the front wheel has stopped. It will display the lap number and the stopped lap time in hours, minutes and seconds.
  • Page 10 » OPERATION INSTRUMENTS SPEED / A2 display mode (average speed 2) A2 shows the average speed based on the TR2 (tripmaster 2) and S2 (stop watch 2) figures. The displayed figure can deviate from the actual average speed if the TR2 figure was changed manually or if S2 was not stopped after the trip.

  • Page 11: Indicator Lamps

    » OPERATION INSTRUMENTS Setting the clock To set the clock, switch the ignition off and select the SPEED/CLK mode. Press and hold the button for 3 seconds. The blinking digits can be changed using the + and – buttons. Press the button to move to the next digit.

  • Page 12: Combination Switch

    » OPERATION INSTRUMENTS Combination switch The light switch has 3 switch positions. [A] = Light off [B] = Low beam light [C] = High beam light The red short circuit button [1] serves to switch off the engine. Leave the switch pressed, until the engine stops.

  • Page 13: Choke

    » OPERATION INSTRUMENTS Choke If you pull the choke button [1] out as far as possible, a bore in the carbure- tor will be opened through which the engine may take in additional fuel. The result is a „fat“ fuel-air mixture of the type needed for cold starts. To deactivate the choke, push the choke button back into its basic position.

  • Page 14: Handlebar Lock

    » OPERATION INSTRUMENTS Handlebar lock The handlebar can be locked by means of the lock located on the control head. Fully turn handlebar to right to lock, insert key, turn to left, press in, turn to right and withdraw. NEVER LEAVE THE KEY INSERTED IN THE LOCK. IF YOU TURN THE STEERING TO THE LEFT THE KEY COULD GET DAMAGED.

  • Page 15: General Tips And Warnings For Starting The Motorcycle

    Accessory parts and baggage can significantly decrease a motor- the rear wheel transmission ratio of your motorcycle. cycle's driving stability. Please observe the following warnings. – ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR 660 SMC ratio 17:40 EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPER- TIES OF THE MOTORCYCLE.

  • Page 16: Driving Instructions

    If the level of brake fluid falls below the minimum value, this indicates a leak in the braking system or completely worn out brake pads. Arrange for the braking system to be checked by a KTM specialist, as com- plete failure of the braking system can be avoided.

  • Page 17: Starting When The Engine Is Cold

    » DRIVING INSTRUCTIONS Starting when the engine is cold 1 Open the fuel tap [1] 2 Swing up the side stand 3 Put the gear in neutral 4 Operate the choke [2] 5 Turn on the emergency OFF switch [4] (Australia only) 6 Go to the left of your motorbike.

  • Page 18: Shifting/Riding

    – IF THE RESISTANCE IN THE HAND BRAKE LEVER OR FOOT BRAKE PEDAL FEELS “SPONGY” (TOO MUCH PLAY), THIS IS AN INDICA- TION THAT SOMETHING IS WRONG WITH THE BRAKE SYSTEM. DON’T RIDE YOUR MOTORCYCLE ANYMORE WITHOUT FIRST HAVING THE BRAKE SYSTEM LOOKED OVER BY A KTM DEALER.

  • Page 19: Fuel

    » DRIVING INSTRUCTIONS Fuel The LC4 engine needs premium gasoline with an octane number of 95 (ROZ) or higher (USA = Premium RON 91). 35 mm USE LEADED OR UNLEADED PREMIUM GRADE GASOLINE (95 OCTANES). NEVER USE ANY GASOLINE HAVING LESS THAN 95 OCTANES BECAUSE IT MAY DAMAGE THE ENGINE.

  • Page 20: Periodic Maintenance Schedule

    IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER!
  • Page 21 » PERIODIC MAINTENANCE SCHEDULE IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2 years every 2500 km at least or 25 hours once a year or 20,000 km Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer Clean and lubricate steering-head bearing and sealing elements...

  • Page 22: Maintenance Work On Chassis And Engine

    MAINTENANCE WORK ON CHASSIS AND ENGINE ALL MAINTENANCE AND ADJUSTEMENT OPERATIONS THAT ARE MARKED WITH A * REQUIRE SPECIALIST KNOWLEDGE. FOR YOUR OWN SECURITY, LET THESE TASKS BE CARRIED OUT BY A KTM-DEALER. AT KTM YOUR MOTORCYCLE WILL RECIEVE OPTIMAL SERVICING BY SPECIALLY TRAINED MECHANICS.

  • Page 23: Check And Adjust Steering Head Bearing

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Check and adjust steering head bearing * Check steering head bearing for play periodically. To check this put motorcy- cle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward.

  • Page 24: Basic Suspension Setup For The Weight Of The Driver

    To achieve maximum handling performance and to prevent the fork, shock absorber, swing arm and frame from being damaged, the basic setup of the suspension components must be suitable for your weight. At delivery, KTM's motorcycles are set to accommodate a driver weighing 70 - 80 kg (wearing full protective clothing).

  • Page 25: Changing The Spring Preloading Of The Shock Absorber

    RIDERS WEIGHT INCLUSIVE GEARS IN KILOGRAM Changing the spring preloading of the shock absorber KTM sets the shock absorber for a driver with a weight of approximately 75 kg (165 lb). If the weight of the driver is more or less than 75 kg (165 lb), you should change the spring preloading [A] accordingly.

  • Page 26: Checking Rubber Ring On The Wp Rear Shock Absorber

    Measure the distance between the two discs at various points around their circumferences. The space should be at least 2.5 mm (0,1 in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit.

  • Page 27: Correct Chain Tension

    IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POS- SIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE.

  • Page 28: General Information About Ktm Disc Brakes

    BRAKE FLUID: KTM fills the brake systems with „Motorex Brake Fluid DOT 5.1“ brake fluid, one of the best brake fluids that is currently available. We recommend that you continue to use it. DOT 5.1 brake fluid is based on glycol ether and of an amber color.

  • Page 29: Changing The Basic Position Of The Handbrake Lever

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the front brake fluid reservoir * Loosen screws [3] and remove lid [4] and membrane [5].

  • Page 30: Replacing The Front Brake Pads

    IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear brake fluid reservoir * When the brake fluid level has dropped to the MIN mark, you need to refill the brake fluid reservoir.

  • Page 31: Changing The Basic Position Of The Brake Pedal

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Changing the basic position of the brake pedal * The basic setting of the foot brake pedal can be changed by turning the end stop roller [1]. Using the push rod [2], the free play on the foot brake pedal must be set.

  • Page 32: Dismounting And Mounting The Front Wheel

    15 Nm. – IF YOU DON’T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE.

  • Page 33: Tires, Air Pressure

    Tire pressure should be checked regularly on a “cold” tire. Proper pressure ensures optimum driving comfort and extends the life of your tires. TIRES – AIR PRESSURE – DO NOT MOUNT TIRES WHICH HAVE NOT BEEN APPROVED BY KTM. OTHER TIRES front rear COULD HAVE ADVERSE EFFECTS ON THE WAY YOUR MOTORCYCLE BEHAVES.

  • Page 34: Check/Set Distance Of The Magnetic Sensor

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Check/set distance of the magnetic sensor The distance between the sensor [1] and the magnet [2] must be between 2 and 4 mm. If not, this could cause the speedometer to malfunction. Loosen the counter nut [3] and correct the clearance by screwing the sensor [1] in or out.

  • Page 35: Replacing Headlight Lamp/Parking Light Lamp

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Replacing headlight lamp/parking light lamp Loosen both rubber bands [1] and tilt headlight mask to the front. Pull the parking light lamp with holder [2] carefully out of the reflector. Pull connector [3] off the headlamp and remove rubber cap [4]. Disengage retain- ing clip and take bulb out of reflector.

  • Page 36: Cooling System

    OF SCALDING! ONLY CONTINUE DRIVING IF THERE IS ENOUGH LIQUID IN THE SYSTEM. STOP AT AN AUTHORIZED KTM WORKSHOP AS SOON AS POSSIBLE TO HAVE THE DEFECT ELIMINATED. CONTINUING TO DRIVE WILL LEAD TO ENGINE DAMAGE. – THE FAN IN THE LEFT RADIATOR IS NOT RUNNING: THE FAN SHOULD RUN FROM A COOLING LIQUID TEMPERATURE OF 98°C (208°F)

  • Page 37: Cleaning Of Air Filter

    [1]. – DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY MOTOREX (BIO DIRT REMOVER AND LIQUID BIO POWER) FOR AIR FILTER MAINTENANCE. FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER.

  • Page 38: Adjusting The Throttle Cable

    » MAINTENANCE WORK ON CHASSIS AND ENGINE Adjusting the throttle cable * The throttle grip should always provide for a backlash of 3-5 mm (0,12-0,20 3-5 mm in). Besides, with the engine running, the idling speed must not change if you turn the handlebar all the way to the left or right.

  • Page 39: Checking The Oil Level Of The Hydraulic Clutch

    Kupplungs-Fluid 75).Biodegradable hydraulic oil is available from your KTM dealer (50ml). KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK- SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY.

  • Page 40: Carburator - Adjust Idling

    » MAINTENANCE WORK ON CHASSIS AND ENGINE CARBURETOR – Adjust idling * Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel [1] and the mix- ture control screw [2].

  • Page 41: Engine Oil

    32°F Only use fully synthetic engine oils that meet the JASO MA quality require- ments (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 viscosity (for tem- 5W/40 10W/50 peratures over 0°C, 32°F) or 5W/40 (for temperatures under 0°C, 32°F).

  • Page 42: Oil, Oil Filter And Screen Filter Change, Bleeding Of The Oil System

    Therefore, we recommend that you have the engine oil changed by your authorized KTM mechanic. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void.
  • Page 43 » MAINTENANCE WORK ON CHASSIS AND ENGINE To facilitate bleeding of the oil system, we have added a hose connection piece and a plastic hose to the set of tools. Take an empty oil can (1 liter) and drill a 7 mm (0.28 in) -diameter hole into the lid. Screw the hose connection piece into the lid from the outside, and secure it from the inside with the M8 hexa- gon nut.

  • Page 44: Trouble Shooting

    We would like to point out that many operations cannot be performed by oneself. In case of uncertainty, please contact a KTM-dealer.
  • Page 45 Fan defective Check if fan operates properly. To do this, start the engine, then bypass the connections to the thermoswitch (bottom right radiator), contact a KTM dealer High oil consumption Buckling gearing ventilation hose Dislocate i.e. replace non-buckling ventilation hose Engine oil level too high Check engine oil level when the engine is warm;...

  • Page 46: Cleaning

    » CLEANING Clean your motorcycle regularly in order to maintain the beauty of its plastic surfaces. The best manner would be to use warm water that has been mixed with a normal trade washing detergent and a sponge. The hard dirt can be removed before with the help of a soft water jet.

  • Page 47: Technical Specifications - Engine

    Only use fully synthetic engine oils that meet the JASO Performance restrictor Slide stop (–) MA quality requirements (see information on the can). KTM recommends Motorex Power Synt 4T in the 10W/50 Stop pump membrane 858 / 2,15 mm viscosity (for temperatures over 0°C, 32°F) or 5W/40...

  • Page 48: Technical Specifications - Chassis

    » TECHNICAL SPECIFICATIONS – CHASSIS CHASSIS 660 SMC Frame Central chrome-moly-steel frame Fork WP Suspension 4860 MXMA Wheel travel front/rear 275 / 260 mm (10.8 / 10.2 in) Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear swing-arm with needle bearing Rear suspension Front brake Disc brake with carbon-steel brake disc, and 4 piston brake caliper...
  • Page 49 » TECHNICAL SPECIFICATIONS – CHASSIS TIGHTENING TORQUES – CHASSIS Collar screw front axle M24x1,5 60 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top M10 (10.9) 45 Nm Shock absorber bottom M10 (10.9) 45 Nm Collar screws brake disk front M6 (10.9) Loctite 243 + 14 Nm Collar screws brake disk rear...

  • Page 50: Head Word Index

    Adjusting the throttle cable ....37 General information about KTM disc brakes ..27 Basic suspension setup for the weight of the driver . . .23 General tips and warnings for starting the motorcycle .14...

  • Page 51: Wiring Diagram

    » SCHALTPLAN WIRING DIAGRAM position light headlight multi-func.-digital-speedometer driving light lamp flasher control lamp front brake switch ye-bl bl-wh bu-wh ye-bl ye-bl re-wh re-bl ye-re ye-re bl-br bl-br re-bl re-wh ye-re wh-gn rear light/brakelight...
  • Page 52 » SCHALTPLAN WIRING DIAGRAM ENGLISH DEUTSCH ITALIANO Capacitor Kondensator Condensatore Driving light lamp Fernlichtkontrolle Spia abbagliante Flasher relay Blinkerrelais Relè indicatori Flasher switch Blinkerschalter Deviatore indicatori di direzione Front brake switch vorderer Bremslichtschalter Interruttore luce ant. di stop Flasher control lamp Blinkerkontrolle spia lampeggiatori Generator...
  • Page 53 » SCHALTPLAN WIRING DIAGRAM ENGLISH FRANCAIS ESPANOL Capacitor Condensateur Condensador Driving light lamp Temion feu route Lampara aviso luces largas Flasher relay Relais de clignotants Relé de la luz intermitente Flasher switch Bouton de clignotants Interruptor de la luz intermitente Front brake switch Contacteur de frein avant Interruptor de luz del freno delantero...
  • Page 54 KTM Group Partner KTM-Sportmotorcycle AG A–5230 Mattighofen www.ktm.at...

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